Automated UV bonding machine, specially designed to bond ferrites to a rotor axle.This specialised bonding machine combines Lormac’s expertise in manufacturing process automation and the skills of Syneo, a company specialising in industrial bonding.

Requirement / Industrialisation of a new manufacturing process.

Industrialisation of the bonding of 4 or 8 ferrites to the rotors of a motor. Annual production in the order of 100,000 parts. The parts were previously assembled using mechanical techniques and the customer asked us to develop a bonding solution which would improve this process. Lormac and Syneo’s combined expertise allowed us not only to propose an innovative assembly process using adhesives, but also to automate production through the use of an automated bonding machine.

Solution / Automated UV bonding machine.

Lormac used their technical expertise to design an automated assembly machine with manual loading and unloading. Once the components to be assembled have been loaded, the rotor is handled by a 6 axis robot at the heart of the automated enclosure. The ferrites are positioned and bonded in place simultaneously when the jaws of the installation close. Operations involving the application of adhesive, bonding, UV curing and concentricity checks result in high productivity levels.

The assembly machine’s performance levels /

• A complete cycle time of only 11 seconds,
• Gravity-fed dosing system,
• Automation of the assembly process using a Syneo bonding solution comprising a high-precision volumetric doser and two UV curing lamps.

Further information.

Welding jig for the assembly of a stainless steel ring in the aeronautics sector. The creation of this assembly / part pick-up support ensures that the parts are accurately positioned while welding.

Requirement / Welding assembly of large parts.

The welding jig needed to conform to two constraints : the large size of the ring and shrinkage caused by welding. The welding template was designed especially for the assembly of a large part (Ø greater than 1500).

Solution / Extendible welding jig.

The welding jig developed by Lormac integrates an extension system designed to pre-stress the ring (larger expansion Ø). This system guarantees that the correct dimensions are obtained.

Another characteristic of this specialised tool is the adaptation of a hydraulic and electrical rotating joint especially designed for this part pick-up application.

Standard SMED rapid tool change-out interface integrated in to an aircraft part machining cell. The integration of a false platform designed by Lormac creates a unique and standardised interface for all manufacturing machines, minimising machine down-time.

Requirement / Speed up manufacturing rotation.

During machining operations, manufacturing changeovers are an indirect cause of down-time. There are three advantages to using a specialised rapid SMED change-out interface for part pick-up and assembly :

• speeding up change-outs,
• improving repeatability when repositioning tools,
• meeting needs in terms of multiple interface / tool “pairs”.

Solution / A single rapid change-out interface.

Development and integration of a false platform creating a standard rapid change-out interface common to all machines. The supplied tool was standardised through the use of zero point mandrels. Positive CAD locking components, these elements are released using hydraulic mechanisms. Lormac designed and installed a comprehensive rapid tool change-out solution for the customer’s application including the supply of a hydraulic release unit, positioning control and a blower.

Characteristics /

• Ø 1600 mm capacity
• 9 false platforms or identical interfaces,
• 8 dedicated tools.

Further information.

Dedicated machining fixture for working vehicle parts on a palletized machine (2 palettes) two spindles. The design of this custom clamping unit made sure that a maximum number of parts could be machined on each pallet rotation and that the cycle time was optimised.

Requirement / Custom part pick-up and clamping.

Custom clamping solution adapted to the geometry of the vehicle parts and meeting constraints in terms of productivity and customer quality :

• part positioning accuracy (two spindles),
• effective clamping,
• maximum size constraints,
• machining in 5 axes with access to multiple tools.

Solutions / Dedicated machining fixture.

Design, manufacture and optimisation of dedicated machining installations for custom clamping and positioning of parts to be machined :

• 2 x 1st OP 4 position installations, both handling 4 axis machining operations: clamping and positioning of 4 parts per tool with holes in the baseplate for pass-through machining.
• 4 x 2nd OP 2 position installations, all handling 5 axis machining operations: clamping of 2 parts per tool.

Further information.

Study, design, manufacture and optimisation of a machining fixture with hydraulic grip and holding. The installation is designed to machine the front and back faces of an aircraft casing in a single operation. Clamping is performed automatically to save time when positioning the part.

Requirement / Clamping adapted to the geometry of the part.

The customer’s specifications included several constraints requiring a dedicated machining installation with a custom grip system. The adaptation of gripping to the particular geometry of the part met the following requirements :

• Machining of the front and back faces in a single operation using the same tool,
• Part had “arms” which were not connected by a casing, causing problems when turning,
• Multiple areas to be clamped,
• Need for precise positioning.

Solution / Hydraulic machining fixture.

The fact that all skill-sets are available internally means that Lormac is autonomous and has limitless capabilities in meeting the most complex needs. The solution designed by Lormac, which was proposed and approved by the customer, was a machining fixture with hydraulic gripping and holding. The double-platform structure allows pipes to be placed between two plates so preventing retention of chips which may affect the precision of machining.The design of this custom machining installation allows stress to be placed on the arms without constraints or defamation. Internal safety system for the clamping system.

Further information.

Design and manufacture of several standard quick change-out models with auto-centring zero point clamping system. Custom part handling solution, integrated with the positioner for the safe change-out of all dedicated assembly tools. The turnkey solution (handler + quick change-out interface) provides productivity gains and improves ergonomics of working conditions for assembly line operators.

Requirement / Handling of large parts.

The aircraft assembly line requires large parts to be handled for riveting. In order to reduce the production series change-out time, the SMED rapid change-out solution must accelerate manufacturing rotation and minimise machinery down-time. In order to provide maximum production flexibility, the handling system can perform several specific part pick-ups. Lastly, sensors are included to manage information storage.

Solution / Standard change-out interface unit.

• A standard zero point quick change-out interface and counter-plate in various part pick-up formats,
• Rapid and safe change-out of dedicated tools,
• Clamped / unclamped position management sensors,
• A unique solution combining specialised part pick-up and an ergonomic handling unit.

Further information.